Weld-Bead Laminate Shaping to Prevent Side Surface Sagging
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Solution Overview
Problem
In existing laminate shaping methods, the thin metal layers can sag and collapse during the welding process, leading to inaccurate lamination of subsequent layers due to heat influence, resulting in poor quality three-dimensional shaped objects.
Innovation Solution
A laminate shaping method where metal layers are formed by sequentially laminating weld beads, and a receiving portion is created on the processed side surface to absorb heat, allowing new metal layers to be laminated on top, thereby preventing sagging and maintaining the shape of the processed side surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal layers are laminated by arc welding, then the three-dimensional shaped object can be formed, but the end portion of the already laminated metal layer melts and sags due to heat influence from the welding material
Solution Approach 1:
A receiving portion is formed in advance at the end portion of the already laminated metal layer before new lamination occurs. This receiving portion acts as a heat sink to absorb excess heat from the welding material, preventing the already laminated portion from melting and sagging while maintaining high lamination efficiency.
2Ease of manufacture
If the thickness of the already laminated metal layer is small, then the lamination process can proceed, but the heat from the welding material causes significant sagging and collapse of the side surface
Solution Approach 1:
The receiving portion serves as an intermediary heat-absorbing structure between the welding material and the thin already laminated metal layer. It mediates the heat transfer by absorbing excess heat, thereby protecting the thin metal layer from thermal damage and maintaining side surface shape stability during the lamination process.
3Productivity
If continuous lamination is performed without interruption, then productivity is maintained, but the heat accumulation causes sagging and prevents accurate lamination of subsequent layers
Solution Approach 1:
The harmful heat energy is extracted from the lamination system by the receiving portion, which absorbs and removes excess heat from the welding zone. This allows continuous lamination to proceed at high productivity while preventing heat accumulation that would cause sagging and quality degradation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively suppresses sagging during metal lamination, enabling the formation of high-quality three-dimensional shaped objects by ensuring accurate lamination and maintaining the intended shape of the processed side surfaces.
Implementation Method 1
a receiving portion projecting in the second direction with respect to the processed side surface, the receiving portion is formed at an uppermost layer of the laminate shaped portion in the first direction, and when the unit step is repeated, in the step of forming the laminate shaped portion, a new metal layer is laminated so as to overlap an upper surface of the receiving portion in the first direction
Implementation Method 2
metal layers formed of weld beads formed by arc welding are sequentially laminated as a laminate shaping method for shaping a three-dimensional shaped object
Data Source
AI summary
A laminate shaping method includes: a unit step repeatedly performed, the unit step including a step of forming a laminate shaped portion by laminating metal layers formed of weld beads, and a step of forming a processed side surface by cutting a shaped portion side surface facing a second direction intersecting a first direction, in which, in the step of forming the processed side surface, the shaped portion side surface is cut so that a receiving portion projecting in the second direction with respect to the processed side surface is formed at an uppermost layer of the laminate shaped portion in the first direction, and when the unit step is repeated, in the step of forming the laminate shaped portion, a new metal layer is laminated so as to overlap an upper surface of the receiving portion in the first direction.